Motorcycle control lever

Abstract

A control lever for operating a control system of a vehicle, such as a brake or clutch of a motorcycle, for example. The lever is especially useful with hydraulic control systems, for applying a force to a hydraulic piston of the control system. Preferably, the lever includes an engagement portion that contacts an end surface of the piston. The engagement portion may be free to rotate with respect to a body portion of the lever such that the engagement portion rolls across the end surface of the piston. Such an arrangement provides improved lever “feel” and substantially prevents transverse loading of the piston. The engagement portion may also include a protruding arm that engages the end surface of the piston, for use with hydraulic control systems where the piston is recessed within a housing.

What is claimed is:  
     
       1. A control lever assembly for actuating a control system of a vehicle, said control system comprising a first portion mounted proximate a hand grip portion of said vehicle and defining a fluid cylinder, a piston movable along a longitudinal first axis of said fluid cylinder, said control lever assembly comprising: 
       a lever body having a finger grip portion, said lever body defining a second axis substantially perpendicular to said first axis, said lever body being rotatable about said second axis to move said piston from a relaxed position to an actuated position, said lever body defining a third axis substantially parallel to said second axis;  
       an engagement portion contacting said piston, said engagement portion rotating about said third axis when said lever body is rotated about said second axis, a force applied by said engagement portion to said piston moving said piston from said relaxed position to said actuated position;  
       wherein said first axis is fixed with respect to said second axis, and said force is substantially aligned with said first axis when said piston is in both of said relaxed and actuated positions.  
     
     
       2. The control lever of  claim 1 , wherein said force is substantially aligned with said first axis throughout a range of motion of said lever body. 
     
     
       3. The control lever of  claim 1 , wherein said engagement portion comprises a bearing assembly. 
     
     
       4. The control lever of  claim 1 , wherein said vehicle comprises an off-road motorcycle and said control system comprises a front brake assembly. 
     
     
       5. A control lever assembly for actuating a control system of a vehicle, said control system comprising a first portion mounted proximate a hand grip portion of said vehicle and defining a fluid cylinder, a piston movable along a longitudinal first axis of said fluid cylinder, said control lever assembly comprising: 
       a lever body having a finger grip portion, said lever body defining a second axis substantially perpendicular to said first axis, said lever body being rotatable about said second axis to move said piston from a relaxed position to an actuated position, said lever body defining a third axis substantially parallel to said second axis;  
       an engagement portion contacting said piston, said engagement portion rotating about said third axis when said lever body is rotated about said second axis, a force applied by said engagement portion to said piston moving said piston from said relaxed position to said actuated position;  
       wherein said force is substantially aligned with said first axis when said piston is in both of said relaxed and actuated positions, and wherein said lever body additionally comprises an intermediate portion and a biasing member, said biasing member urging said finger grip portion into a normal position of said control lever, said finger grip portion being movable relative to said intermediate portion against the biasing force of the biasing member to a deflected position of said control lever.  
     
     
       6. A control lever assembly for actuating a control system of a vehicle, said control system comprising a first portion mounted proximate a hand grip portion of said vehicle and defining a fluid cylinder, a piston movable along a longitudinal first axis of said fluid cylinder, said control lever assembly comprising: 
       a lever body having a finger grip portion, said lever body defining a second axis substantially perpendicular to said first axis, said lever body being rotatable about said second axis to move said piston from a relaxed position to an actuated position, said lever body defining a third axis substantially parallel to said second axis;  
       an engagement portion defining a circular peripheral edge surface about said third axis, said peripheral edge surface contacting said piston, said engagement portion rotating about said third axis when said lever body is rotated about said second axis, a force applied by said engagement portion to said piston moving said piston from said relaxed position to said actuated position, and wherein said first axis is fixed with respect to said second axis.  
     
     
       7. The control lever of  claim 6 , wherein said force is substantially aligned with said first axis when said piston is in both of said relaxed and actuated positions. 
     
     
       8. The control lever of  claim 6 , wherein said force is substantially aligned with said first axis throughout a range of motion of said lever body. 
     
     
       9. The control lever of  claim 6 , wherein said engagement portion comprises a bearing assembly. 
     
     
       10. The control lever of  claim 6 , wherein said vehicle comprises an off-road motorcycle and said control system comprises a front brake assembly. 
     
     
       11. A control lever assembly for actuating a control system of a vehicle, said control system comprising a first portion mounted proximate a hand grip portion of said vehicle and defining a fluid cylinder, a piston movable along a longitudinal first axis of said fluid cylinder, said control lever assembly comprising: 
       a lever body having a finger grip portion, said lever body defining a second axis substantially perpendicular to said first axis, said lever body being rotatable about said second axis to move said piston from a relaxed position to an actuated position, said lever body defining a third axis substantially parallel to said second axis;  
       an engagement portion defining a circular peripheral edge surface about said third axis, said peripheral edge surface contacting said piston, said engagement portion rotating about said third axis when said lever body is rotated about said second axis, a force applied by said engagement portion to said piston moving said piston from said relaxed position to said actuated position, and wherein said lever body additionally comprises an intermediate portion and a biasing member, said biasing member urging said finger grip portion into a normal position of said control lever, said finger grip portion being movable relative to said intermediate portion against the biasing force of the biasing member to a deflected position of said control lever.  
     
     
       12. A control lever assembly for actuating a control system of a vehicle, said control system comprising a first portion mounted proximate a hand grip portion of said vehicle and defining a first fluid cylinder, a piston movable along a longitudinal first axis of said first fluid cylinder, said control lever assembly comprising: 
       a lever body having a finger grip portion, said lever body defining a second axis substantially perpendicular to said first axis, said lever body being rotatable about said second axis to move said piston from a first position to a second position;  
       a shaft fixed to said lever body and defining a third axis substantially parallel to said second axis;  
       an engagement portion rotatably supported by said shaft, said engagement portion defining a contact surface for contacting said piston and being configured to rotate about said third axis when said lever body is rotated about said second axis to move said piston from said first position to said second position.  
     
     
       13. The control lever of  claim 12 , wherein the engagement portion additionally comprises an arm portion, said arm defining said contact surface for contacting said piston. 
     
     
       14. The control lever of  claim 12 , wherein said engagement portion comprises a bearing assembly. 
     
     
       15. The control lever of  claim 12 , wherein said lever body additionally comprises an intermediate portion and a biasing member, said biasing member urging said finger grip portion into a normal position of said control lever, said finger grip portion being movable relative to said intermediate portion against the biasing force of the biasing member to a deflected position of said control lever. 
     
     
       16. The control lever of  claim 12 , wherein said vehicle comprises an off-road motorcycle and said control system comprises a front brake assembly. 
     
     
       17. A control lever assembly for actuating a control system of a vehicle, said control system comprising a first portion mounted proximate a hand grip portion of said vehicle and defining a first fluid cylinder, a piston movable along a longitudinal first axis of said first fluid cylinder, said control lever assembly comprising: 
       a lever body having a finger grip portion, said lever body defining a second axis substantially perpendicular to said first axis, said lever body being rotatable about said second axis to move said piston from a first position to a second position, said lever body defining a third axis substantially parallel to said second axis and a first bearing surface having a first bearing surface area;  
       an engagement portion comprising an arm portion defining a contact surface for contacting said piston, said engagement portion defining a second bearing surface facing said first bearing surface having a second bearing surface area; and  
       a bearing assembly operably positioned between said lever body and said engagement portion to permit said engagement portion to rotate about said third axis when said lever body is rotated about said second axis to move said piston from said first position to said second position, said bearing assembly comprising a plurality of bearing members, each bearing member contacting said first bearing surface and said second bearing surface along a contact surface area, the total of said contact surface area for said plurality of bearing members being substantially smaller than either of said first bearing surface area and said second bearing surface area.